Automotive Design with Respect to Ergonomics

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Automotive Design with Respect toErgonomics

• Ehsan Naseri
  81178607
• Soudeh Yektaee 81195404

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Content

• What is Design?
• Design Process
• Design process For Automotive
• Design process For automotive with respect to
  Human Factors

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Introduction to Design

• A goal- directed problem solving activity (Archer
  1965).
• Design is a interplay between what we want to
  achieve and how we want to satisfy them (Suh
  1990).
• Design is a process of converting information
  that characterize the needs and requirements for
  a product into knowledge about the product
  (Mistree 1992).

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Definition of Design

• Design is
• An art, not a science
• Problem solving, Decision making, Applying
  science
• Creativity imagination vs Heuristic search
• Directing, leading organizing
• Dealing with people team-building
• Negotiating to achieve a satisfactory solution
  optimizing
• Foresight towards production, assembly, testing
  and other processes
• Considering the "bottom line" of costs and
  profit,
• Satisfying needs satisfying the customer
• Ethical and professional conduct

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Various Design

• New Design New tasks and problems are solved by
  new solution principles.
• Revised Design The embodiment design is
  customized/adapted to fit new requirements. The
  employed solution principles are known and
  field-proven .
• Variant Design Size and/or structure of parts
  and assemblies are varied within the limits of
  the already planned system.
• Repeat Design A new start of the production run
  with an unchanged design.
• Robust design A systematic engineering based
  methodology (which is part of quality engineering
  process) that developes and manufactures high
  reliability products at low cost with reduced
  delivery cycle.

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Over the Wall Engineering

• Roles of system engineer
• Need identification customer linkage,
  Management (spec, process, risk, information),
  System design, Integration, RD, leading
  coordinating

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Integrate Product Design

• Integrate People
• Build concurrent engineering teams
• Negotiation in engineering design
• Integrating Processes
• Process Modeling
• Process Reengineering
• Integrating Information
• Database Management Systems
• Information and data mining
• Building a Concurrent Engineering Design Process

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Design Process

• System, subsystem and component design
• Sequential iterative process
• Starts and Ends with the customer
• Comparison and contrast to scientific method
• Need ? Concepts ? Feasibility ? Produce ? Sell
• Time and cost as key factors
• Process of converting information that
  characterizes the needs and requirements for a
  product into knowledge about the product and its
  implied processes.

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Engineering Models of Design
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Design process 1

• Recognition of a customers need
• Market research identifies customers and needs
• RD creates ideas that are relevant to an
  organizations capabilities
• Needs arise from dissatisfaction
• Technology push (examples computers, audio)
• Definition of a problem or Task
• Design specification
• Selecting product ideas
• Compiling the requirement list
• Acquire apply technical knowledge
• Identify resources
• Prioritize design goals continue to refine

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Designs vs Needs
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Design process 2

• Product definition
• Function
• Preliminary requirements list
• Solution requirements
• Cost target and budget

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Design process 3

• Conceptual design
• This phase looks at the function requirement of
  the Product.The function are listed complex
  functions are broken into simpler sub-functions.
• Determines the Principle of Solution.
• It is preceded by a Decision
• Procedure
• Abstract to identify essential problems
• Establish function structures
• Search for working principles to fulfill the
  sub-functions
• Combine working principles into working
  structures
• Select suitable combinations
• Evaluate against technical cost criteria

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Design process 4

• Design embodiment
• It starts from the concept and develops the
  definitive layout for the project
• Evaluate against Technical Economic criteria
• Preliminary layout
• Optimize and complete form designs
• Check for errors and disturbing factors
• Prepare preliminary part list and production
  documents
• Embodiment design is characterized by repeated
  deliberation and verification.
• This requires approach that is progressive as
  well as iterative.
• The checklist
• Function, Working Principle, Layout, Safety,
  Ergonomics, Production, Assembly, Transport,
  Recycling, Maintenance, Costs, Quality control

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Design process 5

• Prepare production documents
• Elaborate detailed drawings and parts list
• Complete production,assembly,transport and
  operating instructions
• Check all documents
• Design review
• Review and redesign focuses on achieving the
  performance, producibility, reliability and cost
  (As compared to what) objectives.
• Competitive benchmarking
• Reverse Engineering of competitors products
• Early bird gets the profit

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Example design process Jack

• My car was not in very bad condition, but the
  original jack was so slender, that I didn't dare
  creep under the car when it was lifted by this
  jack. There was no space for me, anyway! The
  floor of the car was badly rusted, because the
  car had been effected by some sewer gas in the
  garage. I had to cut large sections out of the
  floor and cover them with new steel plate.

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Information

• Space below of car
• Jack point car size

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Available Means
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List of Demands
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Definition of Problem

• We must design a jack, which is able to lift a
  car, which has a weight of 1300 kg, a width of
  1800 mm an a wheel base of 2700 mm. The jack must
  be safe enough, that repair and service
  operations below the lifted car are possible.
• We must design a system, which makes repair and
  service operations possible below a car.
• Functions

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Decomposing into subsystem
Ones muscle power has to be transformed to
lifting force with the sub function 1. Sub
function 2 is used to transmit the combination of
lift and lifting force directly or in transformed
form into the connection points of the car. Sub
function 3 makes the connection with the car. Sub
function 4 keeps the system steady on the ground.
Sub functions 5 and 6 secure the lift and they
make operations below the car safe.
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Alternative subsystems
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Possible combinations
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Decision Table
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Embodiment design
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Detail design
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Review of Design
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Results
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AutomotiveDesign
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Aspects of Designing Car

• Occupant Packaging
• Computer-Aided Ergonomics Design Of car
• Visual Aspects in vehicle Design
• Automotive Seat Design for sitting comfort
• Physical Aspect of Car Design
• Design of symbols for automobile Control and
  Displays
• Informational aspect of vehicle Design

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Occupant Packaging

• Workspace Anthropometry
• Conventional Static Measurements
• 
  anthropologist
• (are taken on the human body in rigid ,
  standarized position)
• Functional Task Oriented Measurements
• 
  Engineer Designer
• (are taken with the human body at work , in
  motion or in workspace attitude and typically are
  expressed as 3 dimensions.)

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Occupant Packaging
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Occupant Packaging
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Occupant Packaging
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Occupant Packaging
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Occupant Packaging
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Driver workspace design
and evaluation models

• Task Oriented Percentile Models
• - Use anthropometric data to Define a user
  population startified across stature , weight
  and
• - Conduct test for specific task(reach, eye
  location) to develop statistical models defining
  spatial requirements

• Manikin Oriented Models
• - Uses anthropometric data to define 95 percent
  male and 5 percent female
• - uses manikins or selected large (95) male
  and small (5) female to define spatial
  requirements

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Driver workspace design
and evaluation models

• - Assume that sample populations defined user
  requirements
• - assumes user needs are
• expressed by a central
• tendency
• with exclusion
• at both ends , for example
• 95 percent accommodation with 2.5 percent
  excluded at each end.

• - Assume that Specified large males and small
  female comprehend all user requirements
• - Assume that 2-D (or 3-D) manikins can
  predict or model human requirements
• - Assume that a given percentile person is
  definable from the some of parts

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Driver workspace design
and evaluation models

• - many level of accommodation are described ,
  but only for the task studied
• - Results in well defined statistical model
  that defines accommodation levels for specific
  task

• - Many task are measured and evaluated , but
  only for a defined small and large user
• - Result in questionably defined geometric
  manikin models that predict accommodation for
  only two extreme percentile people

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Computer Aided Ergonomic Design of automobile

engineers will simulate driver behavior and
measure key criteria such as reach, visibility,
comfort, posture, biomechanics, strength and
anthropometrics. This analysis will enable the
team to make driver-oriented decisions about
cockpit design, while respecting the overall
aerodynamics of the racecar body.
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Simulation with computer

• To optimize cockpit ergonomics, engineers will
  first create a digital model of each driver using
  a combination of laser scanning and manual
  anthropometrical techniques. The resulting
  virtual models will be used to analyze and
  improve specific accommodation issues such as
  driver comfort and security, and accessibility
  and serviceability of components inside the
  cockpit during pit stopswithout the need to
  involve the actual drivers.

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The SAMMIE System

• The SAMMIE system is a computer based Human
  Modeling tool. Its capabilities make it an
  invaluable tool to designers and design teams
  working on products that are used by people. The
  system offers the following advantages
• 3D analysis of fit, reach, vision and posture.
• reduced timescale.
• early input of ergonomics expertise.
• rapid interactive design.
• improved communication.
• cost effective ergonomics

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Automotive Seat Design For Sitting Comfort

• kind of motor vehicles
• 1. Family and personal business sedan
• 2. Minivan and off-road vehicle
• 3. Sport cars
• Three different occupants in the vehicle
• 1)Driver
• 2) Front seat passenger
• 3) Rear set passengers

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Automotive Seat Design For Sitting Comfort

• Criteria for a driver s seat
• 1 the set should position the driver with
  unobstructed vision and within reach of all
  vehicle control
• 2 the seat must accommodate the driver s size
  and shape
• 3 the seat should be comfortable for
  extended period
• 4 the seat should provide a safe zone for
  the driver in a crash

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Why should respect Ergonomics In Design?

• Safety

Safety in a race car is the art of protecting the
human occupant, at whatever cost to the car.
Designing the car to be damaged minimally while
hindering driver safety is definitely the wrong
approach. So how do we protect the driver? Well
first we need to consider the basic physiological
weak points of the human body.
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Safety

• The diagram above shows that pretty much any part
  of the body exposed to the chassis of the race
  car is at risk. Injuries occur because the body
  sustains impacts beyond the G (gravities) level
  that it can sustain.
• The brain is particularly succeptible to injury,
  because it is really just a soft tissue mass
  stored inside a very solid bone container, the
  skull. The key to avoiding injury in the brain is
  to avoid instantaneous decelleration of the
  skull. That is, when the skull strikes something
  hard, it decellerates instantaneously. The brain
  inside unfortunately keeps on moving, causing
  head trauma.
• Neck and spinal injuries also present a serious
  threat to life and career. These "Connector" type
  elements in our body are flexible and
  stretchable, to a point, and can sustain
  tremendous G loads before breaking. However,
  depending on angle of impact, they can break
  rather easily.
• Other bone injuries (breakages) are not as
  life-threatening or career ending, but still are
  to be prevented. The bones in our arms, legs and
  spine are designed to be stressed in tension and
  compression along their length. In the case of
  impacts they are often stressed in shear or
  bending, and therefore snap relatively easily

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Safety In Crash

• First, the driver needs to be supported, so
  movement under normal driving is very limited.
  This means a seat with lateral head support, a
  head rest, and good lower and upper body lateral
  support. Most racing seats provide these three
  elements
• Secondly, the car's chassis needs to hold the
  seat and driver in place, in all situations,
  driving and crashing. This is of course
  accomplished with a chassis mount for the seat,
  and a 5 or 6 point harness.
• Thirdly, measures must be taken to prevent
  intrusion into or the crushing of the driver's
  limbs and extremities. On formula cars, the
  problem of suspension wishbones breaking and
  piercing the driver's legs is solved by
  anti-intrusion panels that prevent pieces of the
  car from intruding into the driver's cockpit. As
  well, the cockpit "Safety cell" needs to be very
  strong. The "Safety cell" is the last piece of
  material between danger and the driver, and so
  should be well constructed, and not prone to
  collapsing onto the driver.
• Finally, the car needs to absorb the energy via
  structures that are crushable. As stated
  previously, the human body does not like to be
  decellerated from 80 or 100 km/h to 0 instantly.
  Therefore, we need to find a way that "quickly"
  decellerates the body. The only possibilities on
  a race car are the structures which surround the
  driver's safety cell. Designing these structures
  to collapse in an impact ensures that G levels
  are reduced because the car is literally
  decellerating over a small distance, instead of
  ZERO distance

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Safety/Ergonomics Design Tips

• Use energy absorbing materials in the collapsable
  crash structure - In lower cost racing cars, most
  of the car is usually built from mild steel.
  Using that same mild steel in areas such as
  wishbones means that impacts will bend the
  material long before it breaks the material,
  meaning energy absorption takes place over a
  longer period.
• For light weight, use a stressed skin over a
  lightweight core material - crushable zones such
  as the nose cone on a formula car can be made
  from balsa, honeycomb or high density styrofoam
  covered with a stressed skin of composites.
• Triangulate the driver "safety cell" to prevent
  collapse - The safety cell can be designed in
  such a way that a catastrophic impact which
  collapses the safety cell, will make the safety
  cell expand away from the driver, instead of
  collapsing it onto the driver. In the case of a
  frontal impact, this would mean the sides of the
  cockpit would expand outward, upward and
  downward, instead of inward.

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Safety/Ergonomics Design Tips

• Use a clear windscreen or bodywork to increase
  vision - using lexan or other non-shattering
  clear material can help increase visibility
  without compromising the function of the
  bodywork. In some cases, the driver can be
  lowered for better CG (center of gravity), and
  the normally opaque bodywork replaced with clear
  lexan, to aid in re-establishing the vision
  field.
• Keep the fuel cell and battery away from the
  driver and danger. Keeping dangerous items away
  from the driver is sometimes very difficult. In
  order to reduce the weight balance change over a
  race, designers will frequently put the fuel cell
  at the CG, so that no matter how empty or full it
  is, it does not cause a front/rear or
  side-to-side weight bias. However, most drivers
  don't like to sit next to fuel. Use secured,
  sealed firewalls between the fuel cell and driver
  compartment, and further, use the safety cell to
  protect the fuel cell from outside intrusions.
• Don't scrimp on safety. Use only top quality
  certified suppliers of safety equipment. The cost
  is perhaps high, but consider how much you value
  your life. Fuel cells (Sanctioning body
  certified), seat belts (5 or 6 point sanctioning
  body certified only!), and driver safety wear
  (Nomex, 2 or more layers minimum! -- anything
  less is like wearing nothing).

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Design Of Symbols For Automobile Control and
Displays

• 1) Digital meters Discreet digital meters
  maximize forward visibility and help create a
  sense of uncluttered spaciousness.
• 2) Triangle-motif steering wheel The
  triangle-motif steering wheel helps harmonize
  exterior and interior design, for a feeling of
  unity throughout.
• 3) Centrally positioned audio panel A 2DIN
  opening for audio components is centrally
  positioned at the top of the instrument panel for
  easy access and visibility.
• 4) Textured dashboard and console The dashboard
  centre, floor console, and front pillars are
  trimmed with a new textured material with a
  refined look and feel.
• 5) Sporty two-tone fascia The sporty two-tone
  fascia adds a touch of pizzazz to the Liana's
  interior.

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Displays
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Displays
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Displays
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Displays
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Reading assignment

• Aesthetics and Engineering Design
• http//design.stanford.edu/PD/kbase/Aesthetics_and
  _Engineering_Design.pdf
• Introduction of design
• http//deed.ryerson.ca/DesignScience/1.html
• design basics in IT
• http//www-3.ibm.com/ibm/easy/eou_ext.nsf/Publish/
  6
• user engineering in IT
• http//www-3.ibm.com/ibm/easy/eou_ext.nsf/Publish/
  1996
• Automotive Ergonomics
• 
  Brayan Peacock Waldemar Karowski
• Sitting posture
• E. Granjin

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